Cebora 947 Plasma Prof 80 User manual

05/03/05

3.300.879/B

Parti di ricambio e schemi elettrici

Spare parts and wiring diagrams

Ersatzteile und elektrische Schaltpläne

Pièces de rechange et schémas éléctriques

Piezas de repuesto y esquemas eléctricos

Partes sobressalentes e esquema eléctrico

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Reserveonderdelen en elektrisch schema

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Pagg. Seiten s

el

.: 65÷67

I -MANUALE DI ISTRUZIONE PER APPARECCHIO DI TAGLIO AL PLASMA PAG. 2

GB -INSTRUCTION MANUAL FOR PLASMA CUTTER Page 7

D -BETRIEBSANLEITUNG FÜR PLASMASCHNEIDGERÄT Seite.12

F -MANUEL D’INSTRUCTIONS POUR MACHINE A COUPER AU PLASMA page 18

E -MANUAL DE INSTRUCCIONES PARA EQUIPO DE CORTE EN PLASMA pag. 24

P -MANUAL DE INSTRUÇÕES PARA APARELHO DE CORTE A PLASMA pag. 30

SF -KÄYTTÖOPAS PLASMALEIKKAUSKONEELLE sivu.36

DK -INSTRUKTIONSMANUAL FOR SKÆREBRÆNDER TIL PLASMASKÆRING side.41

NL -GEBRUIKSAANWIJZING VOOR PLASMASNIJMACHINE pag.47

S -INSTRUKTIONSMANUAL FÖR PLASMASVETS sid.53

GR -

ODHGOS

CRHSEWS

GIA

SUSKEUH

KOYIMATOS

ME

PLASMA sel.

59

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7

IMPORTANT: BEFORE STARTING THE EQUIP-

MENT, READ THE CONTENTS OF THIS MANUAL,

WHICH MUST BE STORED IN A PLACE FAMILIAR

TO ALL USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN

OF THE MACHINE.

THIS EQUIPMENT MUST BE USED SOLELY FOR WELD-

ING OPERATIONS.

1 SAFETY PRECAUTIONS

WELDING AND ARC CUTTING CAN BE

HARMFUL TO YOURSELF AND OTHERS.

The user must therefore be educated

against the hazards, summarized below, deriving from weld-

ing operations. For more detailed information, order the

manual code 3.300.758

ELECTRIC SHOCK - May be fatal.

· Install and earth the welding machine according to

the applicable regulations.

· Do not touch live electrical parts or electrodes with

bare skin, gloves or wet clothing.

· Isolate yourselves from both the earth and the workpiece.

· Make sure your working position is safe.

FUMES AND GASES - May be hazardous to your health.

· Keep your head away from fumes.

· Work in the presence of adequate ventilation, and

use ventilators around the arc to prevent gases from

forming in the work area.

ARC RAYS - May injure the eyes and burn the skin.

· Protect your eyes with welding masks fitted with fil-

tered lenses, and protect your body with appropriate

safety garments.

· Protect others by installing adequate shields or curtains.

RISK OF FIRE AND BURNS

· Sparks (sprays) may cause fires and burn the skin;

you should therefore make sure there are no flam-

mable materials in the area, and wear appropriate

protective garments.

NOISE

This machine does not directly produce noise

exceeding 80dB. The plasma cutting/welding proce-

dure may produce noise levels beyond said limit;

users must therefore implement all precautions required by

law.

PACEMAKERS

· The magnetic fields created by high currents may affect the

operation of pacemakers. Wearers of vital electronic equip-

ment (pacemakers) should consult their physician before

beginning any arc welding, cutting, gouging or spot welding

operations.

EXPLOSIONS

· Do not weld in the vicinity of containers under pres-

sure, or in the presence of explosive dust, gases or

fumes. · All cylinders and pressure regulators used in

welding operations should be handled with care.

ELECTROMAGNETIC COMPATIBILITY

This machine is manufactured in compliance with the

instructions contained in the harmonized standard

EN50199, and must be used solely for professional pur-

poses in an industrial environment. There may be poten-

tial difficulties in ensuring electromagnetic compatibility

in non-industrial environments.

IN CASE OF MALFUNCTIONS, REQUEST ASSISTANCE

FROM QUALIFIED PERSONNEL.

2 INSTALLATION

Remove the machine from its packing, assemble the

wheels and the handle, following the instructions in Fig. 1

Do not use the handle to lift the unit.

2.1 TORCH ASSEMBLY

This power source is suitable only for CEBORA torch-

es and is supplied with model CP90- CP91 (IT-DE Pat.

Pending).

This torch has been manufactured in full observance

of the safety precautions contained in the standard

EN50192. This standard requires that the live nozzle

placed vertically on a horizontal surface may not be

touched by the conventional test probe, the specifica-

tions for which are set forth by the standard itself. In

observance of this requirement, it is now impossible

to use the parts previously manufactured, since it

would not have been possible to avoid contact with

the test probe when using long electrodes and gas

nozzles. A gas nozzle holder has therefore been

designed with a protective tube that prevents any

accidental contact with live parts, and allows the use

of a new long nozzle that can cut in corners or recess-

es. To avoid the hazards created by using the previous

parts, this nozzle holder has been designed with a

left-hand thread, and must therefore be screwed on

counter-clockwise.

Insert the torch fitting into the guard R, then onto the fit-

ting P, firmly tightening the ring-nut to avoid air leaks that

could damage or interfere with smooth operation of the

torch.

INSTRUCTION MANUAL FOR PLASMA CUTTER

Fig.1

8

Do not dent the current pin or bend the pegs of the torch

fitting. A dented pin may not disconnect, while a bent peg

does not allow proper insertion onto the fixed fitting P,

thereby preventing the machine from working.

Use the screws provided to fasten the guard R on to the

panel.

2.2 DESCRIPTION OF DEVICES ON THE MACHINE

A) Power cord

B) Compressed air fitting (1/4" female gas thread)

C) Mains power switch

E) Pressure regulator knob

F) Pressure gauge

G) Thermostat LED

H) Grounding clamp

I) Water trap

L) Low air pressure LED

M) Cutting current regulator knob

N) LED that lights when the nozzle should not be in

contact with the workpiece while cutting.

P) Torch fitting

R) Safety guard

S) Blocked LED; lights when hazardous conditions

arise.

T) Push-button to activate and deactivate the "SELF-

RESTART PILOT" function.

U) Plasma torch.

V) Mains power led.

2.3 SAFETY DEVICES

This system comes equipped with the following safety

devices:

Overload cutout:

To avoid overloads. It is evidenced by the G led con-

tinuosly on (see fig.2).

Pneumatic:

Located on the torch inlet to prevent low air pres-

sure. The LED L lights when tripped (see fig.2).

Electrical:

Located on the torch body, to prevent hazardous voltages

from occurring on the torch when, swirl ring, electrode or

nozzle holder are replaced;

The machine is also equipped with an error detection

system, summarized in the table in paragraph 6.1.1

• Do not remove or short-circuit the safety devices.

• Use only original spare parts.

• Always replace any damaged parts of the machine

with original materials.

• Do not run the machine without its housings. This

would be dangerous to the operator and anyone else

in the work area, and would prevent the machine from

being cooled properly.

2.4 EXPLANATION OF TECHNICAL SPECIFICATIONS

IEC 60974.1 The equipment is built according to these

EN 50192 standards.

EN 50199

N°. Serial number. Must be indicated on any

type of request regarding the device.

three-phase transformer-rectifier

Downslope.

Suitable for plasma cutting.

TORCH TYPE Type of torch that may be used with this

machine to form a safe system.

U

0

. Secondary open-circuit voltage.

X. Duty cycle percentage.

The duty cycle expresses the percentage of

10 minutes during which the welding

machine may run at a certain current I

2

➡

CMV SL GN U T P RH I F B E

Fig.2

9

and voltage U

2

without overheating.

I

2

. Cutting current.

U

2

Secondary conventional voltage with weld-

ing current I

2

This voltage depends on the

distance between the contact tip and the

workpiece.

If this distance increases, the cutting vol

tage also increases and the duty cycle

X% may decrease.

U

1

. Rated supply voltage.

3~ 50/60Hz 50- or 60-Hz three-phase power supply

I

1

Max Max. absorbed current at the corresponding

current I

2

and voltage U

2

.

I

1

eff This is the maximum value of the actual cur-

rent absorbed, considering the duty cycle.

This value usually corresponds to the capa-

city of the fuse (delayed type) to be used as

a protection for the equipment.

IP21 C. Protection rating for the housing.

Grade 1 as the second digit means that this

equipment is not suitable for use outdoors in

the rain.The additional letter C means that

the equipment is protected against access

to the live parts of the power circuit by a

tool (diameter 2.5 mm ).

. Suitable for use in high-risk environments.

NOTES: The machine has also been designed for use in

environments with a pollution rating of 3. (See IEC 664).

2.5 START-UP

The machine must be installed by qualified personnel.

All connections must be made in compliance with

current safety standards and full observance of safe-

ty regulations (see CEI 26-10 CENELEC HD427).

Connect the air supply to the fitting B.

If the air supply comes from a pressure regulator of a

compressor or centralized system, the regulator must be

set to an output pressure of no more than 8 bar (0.8 Mpa).

If the air supply comes from a compressed air cylinder,

the cylinder must be equipped with a pressure regulator.

Never connect a compressed air cylinder directly to

the regulator on the machine! The pressure could

exceed the capacity of the regulator, which might

explode!

Make sure that the supply voltage matches the one

shown on the label applied to the power supply cable.

Otherwise, use the voltage change terminal board inside

the machine (see Fig. 3).

Connect the power cord A : the yellow-green cable wire

must be connected to an efficient grounding socket on

the system. The remaining wires must be connected to

the power supply line by means of a switch placed as

close as possible to the cutting area, to allow it to be shut

off quickly in case of emergency.

The capacity of the cut-out switch or fuses installed in

series with the switch must be equal to the current I

1

eff.

absorbed by the machine.

The absorbed current I

1

eff. may be determined by read-

ing the technical specifications shown on the machine

under the available supply voltage U

1

.

Any extension cords must be sized appropriately for the

absorbed current I

1

max.

S

3 USE

Read the standards CEI 26/9 - CENELEC HD 407 and CEI

26.11 - CENELEC HD 433 carefully before using the

equipment, and make sure the cable insulation is fully

intact. Make sure the trigger has not been pressed.

Turn the machine on using the switch C. The warning

lamp V will light to indicate that the machine is on.

Press the torch trigger briefly to open the flow of com-

pressed air. Now adjust the pressure, shown on the pres-

sure gauge F, to 4.7 bar (0.47 MPa) using the knob E on

the regulator, then lock the knob by pressing it down-

ward.

Connect the grounding clamp to the workpiece.

The cutting circuit must not be deliberately placed in

direct or indirect contact with the protective wire except

in the workpiece.

If the workpiece is deliberately grounded using the pro-

tective conductor, the connection must be as direct as

possible and use a wire of at least the same size as the

cutting current return wire, and connected to the work-

piece at the same point as the return wire using the return

wire clamp or a second grounding clamp placed in the

immediate vicinity. Every precaution must be taken to

avoid stray currents. Use the knob M to select the cutting

current.

Use the nozzle ø1 up to 45/50 A, the nozzle ø 1.2 from

45 to 70 A and the nozzle ø 1.3 from 60 to 90 A.

CAUTION!

• The nozzle must never touch the workpiece with

currents greater than 45/50 A; you must therefore use

the two-pronged spacer Art. 1404.

NOTE: The cutting quality is considerably improved if the

nozzle is held approximately 3 mm from the workpiece.

For practical reasons, it is at times preferable to cut with

the nozzle in contact with the workpiece.

This working technique must not be used at currents

greater than approximately 45/50 A, because it leads

to rapid (at times instantaneous) destruction of the

nozzle hole, causing poor quality cutting.

Make sure that the grounding clamp and workpiece have

fig. 3

10

a good electrical contact, especially with painted, oxi-

dized or insulated sheet metal.

Do not connect the grounding clamp to the part of the

material that is to be removed.

Press the torch trigger to strike the pilot arc.

If cutting does not begin after 2.5 seconds, the pilot arc

shuts off and the torch trigger must thus be pressed again

to restart; If the pilot self-restart function is active, this

takes 5 seconds.

Hold the torch upright while cutting.

When you have finished cutting and released the trigger,

air will continue to leave the torch for approximately 90

seconds to allow the torch to cool down.

It is best not to turn the machine off until this cool-

down period is complete.

Should you need to make holes or begin cutting from the

center of the workpiece, you must hold the torch at an

angle and slowly straighten it so that the nozzle does not

spray molten metal (see fig. 4). This must be done when

making holes in pieces more than 3 mm thick.

During automatic operation (see fig. 5), hold the nozzle

6/7 mm away from the workpiece. After the hole has been

made, move it to a distance of approximately 3/4 mm.

For thicknesses greater than 6/8 mm, the material must

be perforated before cutting.

When making circular cuts, we recommend using the

special compass available upon request. It is important to

remember that use of the compass may make it neces-

sary to use the starting technique described above (fig.2).

Do not keep the pilot arc lit in the air when not needed, to

avoid unnecessary consumption of the electrode, swirl

ring or nozzle.

Turn the machine off when the task is completed.

To cut perforated or grid sheet metal, activate the "Pilot

self-restart" function by holding down the torch trigger T

for at least 3 seconds (LED U on). When you have finished

cutting, keep the torch trigger pressed to make the pilot

arc restart automatically.

Use this function only if necessary to avoid unneces-

sary wear on the electrode and nozzle.

4 CUTTING ERRORS

4.1 INSUFFICIENT PENETRATION

This error may be caused by the following:

• high speed. Always make sure that the arc fully pene-

trates the workpiece and is never held at a forward angle

of more than 10 -15°. This will avoid incorrect consump-

tion of the nozzle and burns to the nozzle holder.

• Excessively thick workpiece (see cutting speed dia-

grams, fig. 6)

• Grounding clamp not in good electrical contact with the

workpiece.

• Worn nozzle and electrode.

• Cutting current too low.

NOTE: When the arc does not penetrate, the molten

metal scraps obstruct the nozzle.

4.2 THE CUTTING ARC GOES OFF

This error may be caused by:

• worn nozzle, electrode or swirl ring

• air pressure too high

• supply voltage too low

• Distance between nozzle and workpiece is too great.

4.3 SLANTED CUT

If the cut appears slanted, turn the machine off and

replace the nozzle.

fig. 4

fig. 5

Fig. 6

11

When the cutting current is above 45 A, prevent the nozz

le from coming into electrical contact with the workpiece

(even through scraps of molten metal), this condition

causes rapid and at times instantaneous destruction of

the nozzle hole, leading to poor quality cutting.

4.4 EXCESSIVE WEAR ON CONSUMABLEE PARTS

This problem may be caused by:

a) air pressure too low compared to the recommended

level.

b) excessive burns on the end of the nozzle holder.

5 HELPFUL HINTS

• If the system air contains considerable amounts of

moisture and oil, it is best to use a drying filter to avoid

excessive oxidation and wear on consumer parts, dam-

age to the torch and a reduction in the speed and quality

of the cutting.

• The impurities in the air encourage oxidation of the elec-

trode and nozzle, and may make it difficult to strike the

pilot arc. If this occurs, use fine sandpaper to clean the

end of the electrode and the interior of the nozzle.

• Make sure that the new electrode and nozzle to be

mounted are thoroughly clean and degreased.

• Always use original spare parts to avoid damaging

the torch.

6 MAINTENANCE

Always cut off the power supply to the machine

before any operation, which must always be carried

out by qualified personnel.

6.1 GENERATOR MAINTENANCE

In the case of maintenance inside the machine, make

sure that the switch C is in position "O" and that the

power cord is disconnected from the mains.

Even though the machine is equipped with an automatic

condensation drainage device that is tripped each time

the air supply is closed, it is good practice to periodically

make sure that there is no condensation accumulated in

the water trap I (fig.2).

It is also necessary to periodically clean the interior of the

machine from the accumulated metal dust, using com-

pressed air.

6.1.1 Troubleshooting

6.3 TORCH MAINTENANCE

In reference to Fig. 7, the parts subject to wear are the

electrode A, the swirl ring B and the nozzle C; these must

be replaced after first unscrewing the gas nozzle holder D.

The electrode A must be replaced when it has a crater in

the center approximately 1.5 mm deep.

CAUTION: do not use sudden force to unscrew the elec-

trode; work gradually to release the thread. The new elec-

trode must be screwed into the seat and fastened in place

without tightening fully.

The nozzle C must be replaced when the central hole is

damaged or wider than that of a new part. Delays in repla-

cing the electrode or nozzle will cause the parts to

overheat, and jeopardize the life-span of the swirl ring B.

Make sure that the gas nozzle holder D is firmly tightened

after replacement.

CAUTION: Screw the gas nozzle holder D onto the torch

body only with the electrode A, swirl ring B and nozzle C

mounted.

If any of these parts are missing, this will interfere with

smooth operation of the machine and, especially, jeo-

pardize operator safety.

6.2 PRECAUTIONS AFTER REPAIRS.

After making repairs, take care to organize the wiring so that

there is secure insulation between the primary and sec-

ondary sides of the machine. Do not allow the wires to come

into contact with moving parts or those that heat up during

operation. Reassemble all clamps as they were on the orig-

inal machine, to prevent a connection from occurring

between the primary and secondary circuits should a wire

accidentally break or be disconnected.

Also mount the screws with geared washers as on the

original machine.

LED STATUS

Flashing lit

Steadily lit

Flashing lit

LED

L

S

CONDITION

Button pressed during

equipment start-up

Missing safety protec-

tion R

Reed contact closed

during equipment

start-up

SOLUTION

Release the button

during equipment

start-up

Mount the protection

Contact technical

service

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64

QUESTA PARTE È DESTINATA ESCLUSIVAMENTE AL PERSONALE QUALIFICATO.

THIS PART IS INTENDED SOLELY FOR QUALIFIED PERSONNEL.

DIESER TEIL IST AUSSCHLIEßLICH FÜR DAS FACHPERSONAL BESTIMMT.

CETTE PARTIE EST DESTINEE EXCLUSIVEMENT AU PERSONNEL QUALIFIE.

ESTA PARTE ESTÁ DESTINADA EXCLUSIVAMENTE AL PERSONAL CUALIFICADO.

ESTA PARTE È DEDICADA EXCLUSIVAMENTE AO PESSOAL QUALIFICADO.

TÄMÄ OSA ON TARKOITETTU AINOASTAAN AMMATTITAITOISELLE HENKILÖKUNNALLE.

DETTE AFSNIT HENVENDER SIG UDELUKKENDE TIL KVALIFICERET PERSONALE.

DIT DEEL IS UITSLUITEND BESTEMD VOOR BEVOEGD PERSONEEL.

DENNA DEL ÄR ENDAST AVSEDD FÖR KVALIFICERAD PERSONAL.

AUTOV TO TMHVMA PROORIVZETAI APOKLEISTIKAV GIA TO EIDIKEUMEVNO PROSWPIKO.V

CODIFICA COLORI WIRING DIAGRAM

CABLAGGIO ELETTRICO COLOUR CODE

A NERO BLACK

B ROSSO RED

C GRIGIO GREY

D BIANCO WHITE

E VERDE GREEN

F VIOLA PURPLE

G GIALLO YELLOW

H BLU BLUE

K MARRONE BROWN

J ARANCIO ORANGE

I ROSA PINK

CODIFICA COLORI WIRING DIAGRAM

CABLAGGIO ELETTRICO COLOUR CODE

L ROSA-NERO PINK-BLACK

M GRIGIO-VIOLA GREY-PURPLE

N BIANCO-VIOLA WHITE-PURPLE

O BIANCO-NERO WHITE-BLACK

P GRIGIO-BLU GREY-BLUE

Q BIANCO-ROSSO WHITE-RED

R GRIGIO-ROSSO GREY-RED

S BIANCO-BLU WHITE-BLUE

T NERO-BLU BLACK-BLUE

U GIALLO-VERDE YELLOW-GREEN

V AZZURRO BLUE

A

B

C

D

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Cebora 947 Plasma Prof 80 User manual

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